energy auditor training level 1

8/16/2019 Energy Auditor Training Level 1

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Energy Auditor Training

Level 1 (EA1)

Manual


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E N E R G Y M A N A G E M E N T T R A I N I N G S E R I E S

Energy Auditor Training

Level 1 (EA1) Manual

© Precicon Automation (S) Pte Ltd63 Hillview Avenue • #10-21

Lam Soon Industrial Building • Singapore 669569Phone 760 0006 • Fax 765 4385http://www.precicon.com.sg

Disclaimer Whilst all reasonable care has been taken to ensure that the description, opinions, listings and diagrams are accurate and workable, Precicon Automation (S) Pte Ltd does not accept any legal responsibility or liability to any person,organization or other entity for any direct loss, consequential loss or damage, however caused, that may be suffered as a

result of the use of this publication.

All rights to this publication are reserved. No part of this publication may be copied, reproduced, transmitted or storedin any form or by any means (including electronic, mechanical, photocopying, recording or otherwise) without prior written permission from Precicon Automation (S) Pte. Ltd.

First Published in Singapore in 2001 (Version 1.10)


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Preface

Thank you for participating in the Energy Auditor Training Level 1 ! We believe you willlearn much on energy auditing from our lecture as well as hands-on session.

It is estimated that the electricity consumption will increase by 4.5% annually in non-

Japan Asia, which is the fastest growth in the world. The very fact that you attend thiscourse, it shows that you are well aware of the emerging importance of Energy, one ofthe most important commodity today. We want to welcome you to this exciting area ofEnergy Management, which has sparked such high level of attention as a result of thetremendous Asia industrial growth.

Why Energy management ? A decade ago, energy is consider a commodity alongside with water, which we buy fromthe utility companies and pay the monthly bills without asking much about how themoney is spent. With the transformation of the industry in term of management &operation, energy has now become one of the aspect that need much effort to consume

it more efficiently. From the experience that we have learnt from our customers andpartners in the energy business, we believe Energy will continue to be one of the mostfocused and high growth area in the next ten years. The following are the reasons :

Deregulation

This is the buzzword which alone has brought the word “Energy Management” into theagenda of the top management of many huge corporations. The energy market of many

Asian countries has been deregulated in the past few years, which allows selectedconsumers to purchase energy freely from a list of energy suppliers which they deem toprovide the best package. In this process, potentially large energy cost saving can beachieved by selecting the most optimum supplier.

Different energy suppliers offer different energy package based on the energy

consumption pattern of their customers. In order to decide on the best party to buyenergy from, the consumer itself needs a clear understanding of their own energyconsumption pattern which in the past only the total kWh is sufficient. Comprehensiveenergy monitoring has now becomes the integral part of this effort to save cost throughDeregulation.

Cost Management

Company management is now aware of the huge energy bill that they are paying everymonth, and the various energy saving programs have been design to reduce this cost.

The various operations will be studied to determine if the operation is energy efficient orany unnecessary energy wastage. Activity Based Costing (ABC) is also a trend which hasbeen increasingly adopted by many companies to determine the production & operation

cost. It has been well proven that these activities if carried out well are able to cut downenergy cost substantially, and this is the reason for the increasing number of companieslooking into implementing these programs.

Green Business Trend

Being environmental friendly in the business operation is now a global business trend forlarge Multinational Companies (MNCs). Environmental standard such as ISO14000have been widely adopted by most MNCs which want to ensure their operation does notadversely affect the well being of the environment. Energy consumption is one of themost indirect environment pollutant. Amount of CO2 gas emitted correlate directly to


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the amount of energy produced to meet the requirement of the consumers. CO2 being agreen house gas brings harmful effect to the environment which includes depleting theozone layer and increase the earth temperature. This is why energy conservation andmanagement has been one of the important agenda in ISO14000 apart from otheraspects such as waste management and emission control.

Total Productive Maintenance (TPM)

TPM is a philosophy which builds a close relationship between Maintenance &Productivity. Production personnel will be instilled a sense of “ownership” of theirmachines together with the maintenance personnel to continuously improve on theproduction.

As the machine operators are given the task of continuous improvement on theirmachine together with the maintenance engineer, machine energy management is one ofthe important activity that can be carried out. Through a simple energy audit on themachine, many potential improvements can be uncovered. The TPM team can nowimplement steps to improve the productivity and the maintainability of the machine.Some of the example may be: Reduce energy consumption by shutting down themachine during idle time, or early detection of machine abnormalities (Predictive

Maintenance).

Our Energy Management Methodology We design our training based on the widely used Six Sigma (6σ ) Concept andMethodology. Six Sigma is the proven structured approach which has helped companieslike Motorola and General Electric to achieve breakthrough performance. Thismethodology is able to provide a frame work to assist a proper implementation ofenergy management program, and a precise way to quantify the results in term of the“sigma” achieved.

Whether or not you are currently using Six Sigma methodology, we believe this trainingconcept will certainly help you to implement a more effective energy management

program after you have completed the course.

What will you get at the end of the training ? The Energy Auditor Training Level 1 (EA1) is designed to provide the trainee afundamental understanding and approach to conduct a simple yet informative energyaudit. The trainees will be able to carry out the role as an internal energy auditor to thecompany and most importantly spearheading energy conservation program.

All participants will be awarded a Certification of Attendance upon submitting a selfproposed energy audit report on their respective facilities.

Thank you once again, and we wish you a pleasant training experience with us !

Yours Sincerely,

Colin KohGeneral ManagerPrecicon Automation (S) Pte Ltd


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Table of Contents

C H A P T E R 1

1.1 What is Energy Management? 1

1.2 What is Energy Audit? 2

1.3 Energy Management vs. Energy

Audit 2

1.4 The Purpose of Energy Auditing 3

C H A P T E R 2

2.1 What is Six Sigma? 4

2.2 Why Six Sigma? 5

2.3 Sigma Improvement

Methodology 5

2.4 Implementing Six Sigma in

Energy Audit 6

C H A P T E R 3

3.1 The Core Element of Energy

Audit 8

3.2 The Properties of Basic Energy

Audit Models 9

3.3 Levels or Types of Energy

Audits 11

3.3.1 Fundamental Audit 11

3.3.2 Intermediate Audit 12

3.3.3 Advanced Audit 12

3.4 Which Type of Survey or Energy

Audits Should I Use? 13

C H A P T E R 4

4.1 The Audit Procedure 15

4.2 Recommended Survey or Audit

Instrumentation 18

4.2.1 Measuring Electrical

System Performance 18

4.2.2 Environmental

Measurements 19

4.3 Presentation of Energy Audit

Results 21

4.3.1 Brief Reporting 22

4.3.2 General Reporting 22

4.3.3 ComprehensiveReporting 22

4.4 Monitoring of Energy Audit

Results 24

C H A P T E R 5

5.1 Audit Instrumentation 25

5.1.1 Measuring Electrical

System Performance 25

5.1.2 Environmental

Instruments 26

5.1.3 Other Tools 26

5.2 Fundamental Audit

Methodology 26

5.3 Recommended Analysis and

Practices 30

5.3.1 Calculating Appliance

Use 30

5.3.2 Examples of Analysis 31

5.4 Recommended Corrective

Measure by Energy Market

Authority, Singapore 33

5.4.1 Lighting 33

5.4.2 Air-Conditioner 34

5.4.3 Air-Compressor 35

5.4.4 Boiler 36

5.5 An Example of Energy Audit 37

5.6 Conclusion 38

References & Bibliography 39


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Index 40

Energy Glossary 41

Conversion Formulae 45

Flow Equivalents 48

Electrical Calculation [10] 50

NOTES 53

ENERGY AUDIT CHECK LIST 56

INFORMATION OF LIGHTING 57

INFORMATION OF ROOM TEMPERATURE

& RELATIVE HUMIDITY 58

INFORMATION OF GENERAL ELECTRICAL

APPLIANCES 59

INFORMATION OF ROOM AIR-

CONDITIONER 60

ENERGY AUDIT WORKSHOP 61


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E N E R G Y A U D I T O R T R A I N I N G - L E V E L 1 ( E A 1 )

CopyriCopyriCopyriCopyright © 2001 Precicon Automation (S) Pte Ltdght © 2001 Precicon Automation (S) Pte Ltdght © 2001 Precicon Automation (S) Pte Ltdght © 2001 Precicon Automation (S) Pte Ltd 1111

Definitions on Energy

Auditing

‘Energy audit’ is only a general term, like ‘a vehicle’.

n principle, the term ‘energy audit’ is well known and widely used. However,there is one problem which can easily lead to misunderstandings of the term. The fact is that the term ‘energy audit’ is only a general term like ‘a vehicle’. What actually meant by the term in an individual conversations can, in

practical term, include an extremely wide range of different applications.

The term ‘energy audit’ is a good general definition but should also be used only assuch[1]. The variety within the family of energy audits should be understood. Theimportance of defining the content and the scope of the audit in more detail shouldbe emphasized in an individual applications. Majority of the different kinds ofenergy audits have been developed on national level and for a specific purpose –like the different types of vehicle: vans, station wagons, sports cars, motorbike etc..

Therefore, although the terminology seems to be similar, it is very likely that theactual subject of the discussion is more or less different from individualapplications.

1.1 What is Energy Management?

In the total quality system, the Energy Management is a vital element of anyorganization. Energy Management in practical terms means placing a focus onenergy as a cost factor in a company. It also implies influencing the consumer’sbehavior in terms of energy, the promotion of an economical energy operation anddisclosing possibilities for energy saving. Furthermore, it is also important inensuring a company’s energy supply, in the form of correct amount, quality andprice.

The aim of the energy management is to achieve organizational objectives atminimum energy consumption and cost [3]. This might sound obvious, but therecan be the danger that focusing on energy efficiency in isolation can lead to other

vital elements or core business needs being overlooked. The key message is simple – energy is there to serve both human and organizations. Human are not here to

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serve energy, but to achieve organizational aims at minimum energy consumptionand cost.

The establishment of routines ensuring a continuous improvement with regard tothe optimization of energy costs is the main task in connection with energy

management. This takes place through the use of a management system involvingdesignated individuals in the organization. These are made responsible for carryingout different tasks within the registration and data processing, the development ofkey figures, information, etc.. The latter is implemented through a plan based onthe energy policy and the objectives established for the operation [3].

1.2 What is Energy Audit?

en er gy au dit \ en-er-je od-et \ noun : The identification of economically-justifiedoperating cost reduction opportunities associated with manufacturing andprocessing plant building, utility, and processing systems – most typically those

opportunities resulting in significantly lowered electrical, natural gas, steam, waterand sewer costs [2].

An energy audit, also called a feasibility study or technical assistance report, istypically needed to identify technically viable and cost effective energy projects that

will reduce energy use and operating costs in the facility[1].

The term energy audit is commonly used to describe a broad spectrum of energystudies ranging from a quick walk-through of a facility to identify major problemareas to a comprehensive analysis of the implications of alternative energyefficiency measures sufficient to satisfy the financial criteria of sophisticatedinvestors.

In recap, an Energy Audit is defined as a systematic procedure that [1]

• Obtains an adequate knowledge of the existing energy consumption profileof the site

• Identifies the factors that have an effect on the energy consumption

• Identifies and scales the cost-effective energy savings opportunities.

The term Energy Audit as such specifies only in general the content of workingmethod but does not define the goal & objective, actual scope, the details of thesurvey or the duration & cost of the survey.

1.3 Energy Management vs. Energy Audit

Energy management is, like other management systems, system oriented – or, itrepresents a procedure or routine that will create results, where the results are


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measurable. Unlike energy management, energy audit is a series of studies on theproperties of energy in a particular site. Therefore, energy audit is the subset ofenergy management, which can be seen clearly in the main components of energymanagement.

The main components of energy management are as follows [3]:

Energy Policy

Energy Analysis

Energy Objectives

Energy Program

Training

Energy Administration

Energy Audit

Annual Report

1.4 The Purpose of Energy Auditing

There are various reason and purpose of conducting energy auditing in the site orbuilding. The primary purpose is to gain benefit from the audit one way oranother. Those benefits can be can be group into the following categories [1]:-

Financial benefits; which reduce the operating cost.

Organizational benefits; which improve the market image of privatebusiness, assists the administration of a building or industrial site toimprove human comfort and productivity as well as process and productquality, enhance the quality of the energy profile based on the ISO 9000series and enhance the structure of the energy or facility managementsprograms.

An environmental benefit; which is the external value, i.e. by reducing theemissions of air pollutants, achieves national or regional energy andenvironmental policies and also the ISO 14000 series.


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The Six Sigma Way

The answer to the question ‘Why Six Sigma?’ was simple:Survival.

ix Sigma at many organizations simply means a measure of quality that

strives for near perfection. Six Sigma is a disciplined, data-driven approachand technique for eliminating defects in any process – from manufacturingto transactional and from product to service. The fundamental objective of

the Six Sigma approach is the implementation of a measurement-based strategythat focuses on process improvement and variation reduction through theapplication of Six Sigma improvement projects. In this chapter, the integration andconceptualized of the Energy Audit Model. Using the concept or the way of SixSigma approach will be described and explained.

2.1 What is Six Sigma?

Six Sigma is a business initiative, not a quality initiative. Six Sigma is an umbrellaterm for a philosophy and way of running a business that improves quality andproductivity and increases profits. The term Six Sigma is a term coined atMotorola, Inc. in the 1980’s. this came after years of continuously improvingproduct and process quality. Motorola used this term as a banner and target toachieve breakthrough results.

Six Sigma is also a rigorous, focused and highly effective implementation of provenquality principles and techniques. Incorporating elements from the work of manyquality pioneers, Six Sigma aims for virtually error free business performance.

Sigma, σ, is a letter in the Greek alphabet used by statisticians to measure the variability in any process. A company's performance is measured by the sigma levelof their business processes.

The ‘Six Sigma’ term also refers to a philosophy, goal and/or methodology utilizedto drive out waste and improve the quality, cost and time performance of anybusiness.

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2.2 Why Six Sigma?

For Motorola, the originator of Six Sigma, the answer to the question "Why SixSigma?" was simple: survival. Motorola came to Six Sigma because it was beingconsistently beaten in the competitive marketplace by foreign firms that were able

to produce higher quality products at a lower cost.

Today, Motorola is known worldwide as a quality leader and a profit leader. AfterMotorola won the Malcolm Baldrige National Quality Award in 1988 the secret oftheir success became public knowledge and the Six Sigma revolution was on. [11]

Today it's hotter than ever.

It would be a mistake to think that Six Sigma is about quality in the traditionalsense. Quality, defined traditionally as conformance to internal requirements, haslittle to do with Six Sigma. Six Sigma is about helping the organization make moremoney. To link this objective of Six Sigma with quality requires a new definition ofquality. For Six Sigma purposes, quality is defined as the value added by a

productive endeavor. Quality comes in two flavors: potential quality and actual quality .[11] Potential quality is the known maximum possible value added per unit ofinput. Actual quality is the current value added per unit of input. The differencebetween potential and actual quality is waste . Six Sigma focuses on improvingquality (i.e., reduce waste) by helping organizations produce products and servicesbetter, faster and cheaper. In more traditional terms, Six Sigma focuses on defectprevention, cycle time reduction, and cost savings. Unlike mindless cost-cuttingprograms which reduce value and quality, Six Sigma identifies and eliminates costs

which provide no value to customers, waste costs.

2.3 Sigma Improvement Methodology

In this Energy Audit perspective, only two method will be implemented, i.e. theDMAIC and DMADV. This section will describe the original characteristic of theSigma Methodology.

DMAIC is the acronyms for Define, Measure, Analyze, Improve and Control. Whereas DMADV is the acronyms for Define, Measure, Analyze, Design and Verify. The similarity of DMAIC and DMADV are both [12]:

Six Sigma methodologies used to drive defects to less than 3.4 per millionopportunities.

Data intensive solution approaches. Intuition has no place in Six Sigma --only cold, hard facts.

Implemented by Green Belts, Black Belts and Master Black Belts.

Ways to help meet the business/financial bottom-line numbers.

Implemented with the support of a champion and process owner.


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The DMAIC can be described as follows:

Define Define the project goals and customer (internal and external)

deliverables

Measure Measure the process to determine current performance

Analyze Analyze and determine the root cause(s) of the defects

Improve Improve the process by eliminating defects

Control Control future process performance

The DMAIC methodology should be used when a product or process is inexistence at the company but is not meeting customer specification or is notperforming adequately.

The DMADV can be described as follows:

Define Define the project goals and customer (internal and external)deliverables

Measure Measure and determine customer needs and specifications

Analyze Analyze the process options to meet the customer needs

Design Design (detailed) the process to meet the customer needs

Verify Verify the design performance and ability to meet customer needs

The DMADV methodology should be used when:

A product or process is not in existence at your company and one needs tobe developed.

The existing product or process exists and has been optimized (using either

DMAIC or not) and still doesn’t meet the level of customer specificationor six sigma level.

2.4 Implementing Six Sigma in Energy Audit

As discussed in Chapter One on the purposes of energy auditing, it can be clearlyseen that the ultimate purposes of Energy Audit and Six Sigma is quite similar, i.e.


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to improve current performance and to reduce operating cost and increase savings.Since Six Sigma is proven to be an effective tools to achieve those purposes, hencethe concept of Six Sigma DMAIC and DMADV seems to be the best adoption forand implemented into Energy Audit Model. The Six Sigma DMAIC process is animprovement system for existing processes falling below specification. Whereas,

the Six Sigma DMADV process is an improvement system used to develop newprocesses or products at Six Sigma quality levels.

In the Energy Audit Model, DMAIC would be best used in the Fundamental andIntermediate level of auditing because it is the most economical process and also itinvolve the low level of implementation which the main objective is to improvecurrent performance without involving major investment or changes in theoperation. However, after the implementation of DMAIC has been done and stilldoes not produce any further improvement, then the DMADV methodologyshould be applied. The DMADV methodology would then be involved in majorchanges and investment in the energy audit model, with the hope that it would helpthe organization to achieve the ultimate purpose and objective of energy policy in

the organization itself. Hence, this DMADV methodology is more suitable forIntermediate and Advanced level of auditing. The details of the proposedmethodology will be discussed thoroughly in the respective section. The followingdiagram display the flow of DMAIC and DMADV in general form.

FIGURE 2.1 : The DMAIC and DMADV of Energy Audit.


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Basic Energy Audit

Models

If any of these elements is missing, the activity is not an Energy Audit but some other kind of survey or consultant

work.

nergy audits can take many forms, from superficial inspections tocomprehensive engineering studies. This chapter focuses on the basicenergy audit models and various type of audit that is available in thecurrent practices. The importance of understanding the various types of

energy audit will enhance the selection of the proper auditing method for individualpremises.

3.1 The Core Element of Energy Audit

To be able to make some restrictions to what approaches can be called energyaudits, there are some requirements that must be fulfilled. The basic requirementfor a working method of an Energy Audit is called a Core Audit [1].

The Core Audit is the heart of all possible energy audits and includes the

following steps of:-

Evaluating the current energy performance

Identifying of energy saving possibilities

Reporting.

If any of these elements is missing, there is no Core Audit and the activity is not anEnergy Audit but some other kind of survey or consultant work [1]. Figure 3.1describes the core element of energy audit.

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FIGURE 3.1 : The Core Audit.

3.2 The Properties of Basic Energy Audit

Models

When conducting energy audit, there are different levels of instruction for auditingand it varies according to different focus of a site or building. The purpose ofintroducing the basic energy audit models is to avoid misunderstanding andconfusion over the different approaches. The understanding of the term ‘model’ inthis context indicates that there is a set of agreement in features or requirements

which are designed for specific types of energy audit application. In a model, thegoal and objectives, actual scope, the details of the survey or the duration & cost ofthe survey are defined. Hence, the criteria of a ‘model’ should be fulfilled by thosedifferent practices and procedures, which is a good term to be used in order toseparate the standard procedures from the ‘do-as-you-like’ procedures [1].

In the Basic Energy Audit Models, the following properties are defined:-

The goal and objective

The scope

The details of the survey

The duration and cost.

Although the basic models can be applied in practice, these Basic Energy AuditModels should be seen more as modeling tools than actual adaptable workingmethods. The basic models can present the next level of accuracy to the generalterm energy audit by defining the goal & objective, scope, details of the survey and


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the duration & cost. There is a significant difference in understanding if we speakabout just a vehicle or about pick-ups, bus or car, as described in Chapter 1.

The goal and objective of an energy audit may varies according to the purposes forconducting the energy auditing, i.e. either for general purposes such as pointing out

the major savings areas or for describing in detail the actual saving measures so thatthey can be implemented easily. This goal and objective may be either survey andstudy the areas of possible energy savings or analyzing in detail the individualenergy saving measures for further implementation.

The scope of an energy audit may be different because an energy audit may cover asite or a building in various ways. At the ‘narrowest’, an energy audit coverstypically only one specific system or a process, whereas at the ‘broadest’ scope, itcovers everything inside the site fence. Between these ‘narrow and broad ends’there are energy audits that deliberately ignore some areas or issues.

An energy auditor can use ‘general or a comprehensive’ approaches when looking

for saving potential in which it describe the detail of the survey. The detail of theaudit is connected to the audit model, and is normally directly related to theduration and cost spent on the project.

The cost of an energy audit is based on the auditors’ fee, the labor cost of theclient’s own personnel, auditing instrumentation or other indirect expenses whichrequired to conduct the energy audit. The duration of the project can ranged fromfew days to few years depending on the types of auditing. The duration and cost ofthe energy auditing can be either ‘ice or gold’, i.e. cheap and short period orexpensive and extremely long period.

These properties of energy audit models are illustrated in Figure 3.2.

FIGURE 3.2 : The Properties of Basic Energy Audit Models

The Goal and Objective

The Scope

The Details of the Survey

The Duration and Cost

To Study To Implement

Narrow Broad

General Comprehensive

Ice Gold


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3.3 Levels or Types of Energy Audits

Three common audit levels are described in more detail below, although the actualtasks performed and level of effort may vary with the auditor providing servicesunder these broad headings. The only way to insure that a proposed audit will

meet your specific needs is to spell out those requirements in a detailed scope of work. Taking the time to prepare a formal solicitation will also assure the buildingowner of receiving competitive and comparable proposals.

The following table demonstrates the different audit levels as compare to theirrespective characteristic. The details of each characteristic will be discussed in thefollowing section.

TABLE 3.1: Energy Management Framework

3.3.1 Fundamental Audit The fundamental audit, alternatively called a simple audit, preliminary audit,screening audit or walk-through audit, is the simplest and quickest type of audit. Itinvolves minimal interviews with site operating personnel, a brief review of facilityutility bills and other operating data, and a walk-through of the facility to becomefamiliar with the building operation and identify glaring areas of energy waste ofinefficiency.

Typically, during this type of audit, it will only cover the major problem areas.Corrective measures are briefly described, and quick estimates of implementationcost, potential operating cost savings, and simple payback periods area alsoprovided. This level of detail while not sufficient of reaching a final decision onimplementing a proposed measure, is adequate to prioritize energy efficiencyprojects and determine the need for a more detailed audit.

In recap, it is a visual inspection of the facility is made to determine maintenanceand operation energy saving opportunities plus collection of information todetermine the need for a more detailed analysis. Referring to the Table 3.1, the best

LevelsCharacteristic

Fundamental Intermediate AdvancedMethodology DMAIC DMAIC/DMADV DMADV

Scope Machine/Equipement ProductionLine/Departmental

Plant/Building

Monitoring&

Measurement

Low Cost DataLogger

On-line Monitoring Web-based/Remote

T e c h n o l o g y

Control Operational Low Cost Automation

CapitalInvestment

Cost Low Moderate High Timeframe One-off Mid-term Long-term


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methodology which is suitable is the DMAIC steps. This is because in this level,there will not be major changes in the existing system but only an operationalimprovement to the current performance, which involve low cost investment andthe duration is very short. Moreover, the scope of involvement or concentration,not limited to the specific area, is normally within the machine or equipment level

and the technologies used are usually the low cost data logger.

3.3.2 Intermediate Audit

The intermediate audit alternatively called a mini-audit, general audit, site-energyaudit or complete site energy audit expands on the fundamental audit as describedabove by collecting more detailed information about facility operation andperforming a more detailed evaluation of energy conservation measures identified.Utility bills are collected for a 12 to 36 month period (if available) to allow theauditor to evaluate the facility’s energy/demand rate structures, energy usageprofiles and trending. Additional metering of specific energy-consuming systems isoften performed to supplement utility data. In-dept interviews with facility

operating personnel are conducted to provide a better understanding of majorenergy consuming systems as well as insight into variations in daily and annualenergy consumption and demand.

This type of audit will be able to identify all energy conservation measuresappropriate for the facility given its operating parameters. A detailed financialanalysis is performed for each measure based on detailed implementation costestimates, site-specific operating cost savings, and the customer’s investmentcriteria. Sufficient detail is provided to justify project implementation.

In recap, this type of audit requires tests and measurements to quantify energy usesand losses and determine the economics for changes. Referring to Table 3.1, the

most suitable steps for this level could be either DMAIC or DMADV, dependingto the requirement of the organization. This is because if the DMAIC steps couldnot further improve current performance, hence the DMADV steps should beapplied. However, with this options, the cost of investment in this level should bekept moderate and not too expensive because the scope of auditing does notinvolve the whole plant but merely production line or departmental levels.Moreover, the technologies that will be applied at this level are usually semi-permanent based tools because of the timeframe of this audit, i.e. mid-term whichis usually within 1-3 years. The mentioned tools are more suitable if it can bemonitored online and the implementation of low cost automation could be appliedtoo in order to further improve the energy performance in the organization.

3.3.3

Advanced AuditIn most corporate settings, upgrades to a facility’s energy infrastructure mustcompete with non-energy related investment for capital funding. Both energy andnon-energy investments are rated on a single set of financial criteria that generallystress the expected return on investment (ROI) [8]. The projected operatingsavings from the implementation of energy projects must be developed such that


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they provide a high level of confidence. In fact, investors often demand guaranteedsavings.

The advanced audit alternatively called an investment-grader audit, detailed audit,maxi audit, or technical analysis audit, expands on the intermediate audit as

described above by providing a dynamic model of energy use characteristics ofboth the existing facility and all energy conservation measures identified. Thebuilding model is calibrated against actual utility data to provide a realistic baselineagainst which to compute operating savings for proposed measure. Extensiveattention is given to understanding not only the operating characteristics of allenergy consuming systems, but also situations that cause load profile variations onboth an annual and daily basis. Existing utility data is supplemented withsubmetering of major energy consuming systems and monitoring of systemoperating characteristics [8].

In recap, this type of audit contains an evaluation of how much energy is used foreach function such as lighting, process, etc; and also requires a model analysis such

as a computer simulation, to determine energy use patterns and predictions on ayear-round basis, taking into account such as variables weather data. Referring to

Table 3.1, the best applied steps could be DMADV because in this level, there willbe major changes in the plant, so that maximum improvement from the currentenergy performance could be achieved and the duration is also very timely andlong, usually more than 3 years. The main objective for this level is to ensure thatthe capital investment are well planned and there will be maximum investmentreturn which is in according to the energy policy of the organization. Moreover,the ‘permanent’ monitoring and measurement tools are usually installed in the plant

with the capability of continuous monitoring , either through internet or remotemonitoring system, to constantly ensure that the optimum steps are taken andenergy performance are kept at the best level.

3.4 Which Type of Survey or Energy Audits

Should I Use?

The type of survey or audit to use will be determined by several factors. Thepurpose, reason, or need for performing a survey or audit will help determine

which type is required for each project. For example, if the building owner orproperty manager simply wants a ‘checkup’ of the energy systems or wants to knowif there is potential for a energy system upgrade that will pay back in a certain time,then a fundamental audit will satisfy these needs. However, if the systems havebeen in place for more than 20 years and not much has been done to upgrade tonewer technology, then the advanced audit is more suitable. The type of buildingcan also help determine the type of survey or audit. The cost of the survey or auditcan also be a factor in deciding which type of survey to use. The size and scope ofa facility will also influence the decision. Intermediate audits are commonly usedfor schools, hospitals, hotels and restaurants. However, a college campus withmany different building types, built over several decades, will benefit most from an


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advanced audit. Also, when the client/customer wants to explore several upgradeoptions, the advanced audit is most suitable.

The more data required, the more measurements needed – and moremeasurements require more analysis. As the need for more data and

measurements becomes apparent, the auditor is moved up the hierarchy fromfundamental to advanced audits. Firms that perform audits on a regular basis havelittle difficulty deciding which type of survey or audit is best for any given project.

This decision will be based on their past experience involving many differentbuilding sizes and types, the scope of the upgrade, and the cost of the audits.

The following table proposed a list of questions, which help to determine the levelof audit that best suits your needs.

TABLE 3.2: Proposed Recommendation of Energy Audit from California EnergyCommission [9].

Questions to determine whichlevel of audit needs

We recommend this ifthe answer is “ Yes ”

We recommend this ifthe answer is “ No ”

Do you want a general analysisof the potential for energyproject in the facility?

Fundamental Energy Audit

Intermediate Energy Audit

Do you already have an energyaudit completed?

Existing studies mayonly need to beupdated to get projectfunded.

Fundamental audit,Intermediate audit or

Advanced audit.

Have some energy efficiencyprojects been installed?

Intermediate auditfocusing on specific

projects not previouslyanalyzed

Fundamental audit,Intermediate audit or

Advanced audit.

Do you have limited funds tospend on an audit?

Fundamental orIntermediate Audit

Advanced audit.

Do you know what projectsyou want to implement?

Intermediate Audit Fundamental or Advanced audit.

Do you want a document thatserves as an energy plan foryour facility?

Advanced audit Fundamental orIntermediate audit

Are you concerned aboutaccuracy of energy projectsavings and cost?

Advanced audit Intermediate audit


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Energy Audit

Methodology

An Energy Audit is NOT done once and for all.

n energy audit is not done once and for all. It is an ongoing process ofcomparison between theory and practice, leading to an ever-improvingunderstanding of what energy is being used, why it is being used, how it isbeing used and at what cost.

By understanding in detail the ways in which energy is utilized in a factory, waysand means of effecting savings can be identified. Hence, this chapter will focus onthe methodology of energy auditing to achieve the ultimate goal of the energymanagement.

4.1 The Audit Procedure

The main purpose of having defined the audit procedure is to covers all basicactions from the beginning of the actual audit work to the reporting and finishingof the project. The procedure in practice varies according to the audit model in useand to the possible application or interface, into which the energy audit isconnected. The main objective regulating the audit procedure is to ensure thequality and conformity of the audits within an audit program.

A successful energy audit starts with a detailed site investigation to observe anddetermine when and where your facility uses energy. Each energy consumingsystem is fully characterized so that potential improvements can be quantified interms of both energy and cost savings. Several levels of calculation methods areapplied to quantify energy savings.

Plant engineering and maintenance or facility personnel are interviewed since they,above all persons, understand the operation of the building, where the problemslie, and usually what the energy efficient solutions are. Field measurements ofactual conditions are made to substantiate system operating parameters. Inaddition, in order to clearly communicate the measures under evaluation, a

Chapter

4


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photographic record of the building envelope and major system components iscompiled.

As mentioned in Chapter 2, basically the audit procedure can be divided into twotypes of steps, i.e. the DMAIC or DMADV. Depending on the requirement and

the need of the organization, the auditor has the choice to choose betweenDMAIC and DMADV. However, there are difference between Six SigmaDMAIC and DMADV, as discussed in Chapter 2. Nevertheless, those steps willbe conceptualized and incorporated into the energy audit procedure.

For the DMAIC, the generic statement for each steps are as follows:-

Define the properties of Energy Audit; i.e. to define the goals and objectives,the scope, the details of survey and the duration and cost of the audit level.

Measure , monitor and survey the site to determine current performance ofenergy in the proposed site.

Analyze and evaluate the energy performance to determine whether does itmeet the organization requirement on energy performance and to identifythe root cause(s) of the low performance.

Improve energy performance by identifying the possibilities steps in energysaving

Control future process performance by proper documentation in reportingand continuous monitoring.

FIGURE 4.1 : Five Distinct DMAIC Steps of Energy Audit Procedure


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The generic statement for DMADV steps are as follows:-

Define the properties of Energy Audit; i.e. to define the goals and objectives,the scope, the details of survey and the duration and cost of the audit level.

Measure , monitor and survey the site to determine current performance ofenergy in the proposed site.

Analyze and evaluate the energy performance to determine whether does itmeet the organization requirement on energy performance and to identifythe root cause(s) of the low performance.

Design and re-engineered the existing system to enhance the energyperformance in the plant/building.

Verify the design performance and ability to meet the targeted energyperformance level

FIGURE 4.2 : Five Distinct DMADV Steps of Energy Audit Procedure

As described earlier, the first three steps of these DMAIC and DMADV share the

same generic statement because those steps are the necessary steps to determine which steps should follows next. With the results from the analysis, the auditor hasthe determine the next steps, which can be either improvement steps, i.e. DMAIC,or redesign the whole system in the plant using the DMADV steps. The choice ofchoosing either steps very much depending on the engineering judgment of theauditing team. However, one can follow the suggested procedure as tabulated in

Table 3.1, which is suitable for any organization to adopt it..


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4.2 Recommended Survey or Audit

Instrumentation

The requirement for an energy audit to quantify as well as to identify where energy

is being used necessitates measurements. These measurements require the use ofinstruments. The basic instruments used in energy audit work are described below.Normally, these instruments are portable, durable, easy to operate and relativelyinexpensive.

With the advancement of technology in the electronic world today, theseinstruments are more sophisticated in its performance and simple to used, and inshort, it is also known as ‘Plug-n-Play’ (PnP) concept.

While being similar, many of the instruments considered operate differently. Forthis reason, detailed operating instructions for all instruments must be consultedand staff should familiarize themselves with the instruments and their operation

prior to actual audit use.

4.2.1 Measuring Electrical System Performance To conduct an electrical survey, there are few parameters, which normally requiredin order to perform the analysis. Those parameters are ampere, voltage, real power(W), reactive power (VAR), apparent power (VA), power factor and powerconsumption (kWh). The parameters can be either from the single phase or threephase system, depending on the equipments or monitoring site. Most of theinstruments should be easily attached and removed. These instruments aredescribed below.

4.2.1.1 Energy Meter

In order to do an Energy Audit, it is natural that the Energy Meter is the first toolthat you should come into your mind. Choosing the right tool for the right job mayneed careful consideration.

There are essentially two main groups of Energy Meter which serve to addressdifferent needs of the Energy Auditor. They are the portable type and thepermanently install type.

Portable type Energy Meter comes in a form of a handheld with the option havinga limited memory build in for data storage. This type of device is ideal if the Energy

Auditor wish to obtain quick but coarse energy data from his building. He is able tomove around the building and collect energy data which can help to have a first

level understanding of the existing condition. While the portable meter is an handytool to acquire data, it often time is not able to capture enough data or trending toallow a more in depth behaviour of the system.

Permanently installed Energy Meter, on another hand, is able to provide the energyauditor with a wealth of data for more in depth analysis. However, permanentlyinstalled meter requires a higher monetary investment in term of purchasing themeters as well as installation work. Permanently installed meter has ranged from


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traditional analogue meter to digital meter which allows long distancecommunication that eliminate the meter reading work.

With an energy meter which is able to provide a broader spectrum of measurementapart from energy consumption, other form of saving can be achieve.

Example: An energy meter which also measure current and power factor may beable to give diagnostic information about an air-con compressor which hasunbalance load and poor factor. By conducting a thorough check on the system,breakdown may be prevented which may cause disastrous effect in a missioncritical application such as clean room and internet data centre (iDC).

FIGURE 4.2 : An Example of Permanently Installed Power Meter (Courtesy of VerisIndustries, LLC.)

FIGURE 4.3 An Example of Permanently Installed Power Meter (Courtesy of ElectroIndustries/GaugeTech)

4.2.2 Environmental MeasurementsIt has been proven that substantial energy cost can be saved just by carrying outsome operational adjustment, especially in the area of air-conditioning system.

Studies have revealed that many buildings are having air-con rooms which aremuch too cold for the comfort of the occupants. This findings establish a startingpoint for the energy auditors to tackle the energy consumption by measuring theenvironmental parameters such as temperature.

To maximize the system performance, knowledge of the environmental parametersis important. Those information are such as temperature of a fluid, surface, light


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density, relative humidity, indoor air quality, etc. Several types of those devices aredescribed in this section.

FIGURE 4.4 : An Integrated RH/Temp/Light Logger (Courtesy of Onset ComputerCorporation.)

4.2.2.1 Light ON//OFF Logger

Light ON/OFF Logger provides information on the status of lighting in aparticular location. This is a tool which can be used to reduce the unnecessary ONtime of lighting which can be easily implemented by fine tuning the daily operationor install automatic timer to shut down the lightings.

4.2.2.2 Temperature / Humidity Logger

This is the basic tool which any Energy Auditor will require to have thetemperature and relative humidity of a location. As have been mentionedpreviously, many air-conditioned buildings have found to have temperature whichis way too cold for the comfort of the occupants. The temperature/humidity loggercan effectively identified places where the temperature & humidity has been “over-conditioned” and resulting in wasting energy unnecessarily.

The Singapore local energy code has specified a max/min dry bulb temperature of

25.5°C /22.5°C and a relative humidity of max 70% for air-conditioned space. This can be used as a reference on how efficient the energy has been used on theair-con system.

FIGURE 4.5 : Different types of Air Quality Sensors (Courtesy of Veris Industries, LLC)

4.2.2.3

Carbon Dioxide Sensor

Another parameter which dictate how comfortable a room condition is, apart fromtemperature and humidity is the Carbon Dioxide (CO2 ) level. These sensors can beused to check if the air-con has been turn on unnecessarily. Should the sensorsenses very low CO2 content, it can be safely concluded that no people is actually


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occupying the room, and proper system can be implemented to switch off the air-con or lighting accordingly to save energy.

4.2.2.4 Infrared Thermography

Infrared Thermographic Camera has been widely used traditionally as a diagnostic

tool to locate faulty parts or loose switch gear connection. It is, however, able to beused as a tool to locate area where hidden energy wastage is taking place.

By rectifying problems such as loose switch gear connection and leakage in the air-con system, the overall efficiency of the system can be improved and much energy

wastage can be avoided.

FIGURE 4.6 : Infrared Camera (Courtesy of ITC International)

FIGURE 4.7 : Infrared Thermography image showing overheating in a motor (Courtesy of ITC International)

4.3 Presentation of Energy Audit Results

An energy audit is only as good as the quality of the final report in regardless tohow accurate and precise the data and how careful and comprehensive thecalculations. An energy audit report is essentially like a sales document. Itspurpose is to ‘sell’ management on the idea of investing money in energyconservation measures in competition with other investment alternatives. Like allgood sales material, it must be concise, direct and convincing.

In principle, the reporting of an energy audit can be done at three different levels. The three options described in the following are also closely connected to the


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thoroughness of the audit work as well as to the program level properties ofmonitoring and quality control.

4.3.1 Brief Reporting Typical brief reporting usually is of the following types or a combination of them

[1]:

A summary

A check-list

A statement

This type of reporting is very brief, which usually very focused and also technicallysound. It may include simple graphs and tables for explanation. It is most suitablefor the fundamental energy audit model. Moreover, it concentrates strictly on thesuggested energy saving measures whereas the other options often describe the

technical systems of the building.

4.3.2 General ReportingGeneral Reporting consists of the following [1]:

Concentrates on the detected energy saving measures

Includes descriptions of the proposed energy saving measures (savings andcosts)

Shows the present consumption figures

Introduces the site very briefly

As compare to brief reporting, the general reporting gives the management a quitegood illustration on the current situation. It still does not go into the detaildescriptions of the technical systems but all suggested energy saving measures arepresented at a level which gives the management some concrete data for decisionmaking.

4.3.3 Comprehensive ReportingComprehensive reporting consists of the following information [1].

Includes a comprehensive description of the site (systems, operation,

production)

Presents a breakdown of the total energy consumption

Introduces all profitable energy saving measures in detail, including somecomments on implementation, saving calculations, cost estimates

Ranks the saving measures according to e.g. simple payback time


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Shows a comparison of the energy consumption data with statistical values,benchmarking indexes, etc.

Includes tables and graphs of measured values to improve the information value of the report.

Comprehensive reporting is suitable for all detail analyzing models. On the basis ofthe information presented in the comprehensive reporting, all the proposed energysaving measures can be either implemented, or at least the decision ofimplementation can be made. All calculations are presented with thecorresponding basic criteria so that the applicability of the suggested savingmeasures can be checked [1].

Table 4.1 shows a suggested outline for a typical energy audit report. The reportshould begin with an executive summary, which briefly describes the proceduresthat were carried out and concentrates primarily on the final results. The executivesummary should contain a table of energy conservation project recommendations

listed in order of priority.

TABLE 4.1: Suggested Outline for an Energy Audit Report

Executive SummaryChapter 1: Introduction to the Energy Audit ProgramChapter 2: Energy Audit Procedures and MethodologyChapter 3: Description of the Plant Energy Distribution/BreakdownChapter 4: Analysis of Energy Conservation OpportunitiesChapter 5: Recommendations/Suggestions for Project Implementation

Chapter 6: Conclusion Appendixes:Data CompilationList of EquipmentsSample Calculations

The concept of the audit and what it is intended to produce should be described inthe introductory chapter. Moreover, it should also familiarize the reader with theorganization energy systems . It should be kept in mind that not many reader willhave the intimate knowledge of the details of the process acquired by the membersof the audit team. Therefore, the introduction should include a listing of the major

points of energy use within the process. This will lead into a discussion in the nextchapter of the points of concentration of the audit.

The general procedures and methodology carried out in the audit should bedescribed following the introduction. The steps for obtaining the data should beoutlined in brief and it is not necessary to include the detailed data here. Forexample, the measurements and methods used to conduct lighting tests should be


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summarized, but the tabulations of actual test data should be included in theappendix.

The following chapter should recap the distribution of energy use in theorganization. Calculation procedures need not be covered at great length, although

they might be described briefly; example calculations can instead be presented in anappendix. The primary objective of this chapter is to justify quantitatively themajor points of interest. Energy distributions can be presented either in tabularform or graphically.

The analysis of the energy conservation opportunities that are considered in thestudy should be cited in the following chapter. The summarized results of theenergy savings calculations and economic evaluations for each item should beincluded too. The results can be presented primarily in tabular form.

The final chapter of the report should contain the priorities and recommendationsfor implementation of energy conservation opportunities immediately or near

future. The priority assigned to each item should be explained so that necessarycorrective steps can be taken. A short payback period will not always be the solecriterion in setting priorities. Since this chapter is really the high point of the report,it is expected that much of the executive summary will be drawn from it, and hencea certain amount of redundancy is acceptable.

Eventually the report should include appendixes that contain most of the detaileddata, calculations, list of equipments used, and other material valuable for futurereference but not essential to a general understanding of the audit and its results. Ifthe report is too lengthy, these appendixes might be incorporated in a separate

volume.

The importance of good reporting should be recognized early in the planning ofthe audit, and a substantial amount of time and effort must be devoted to it. Alltoo often, preparation of the report is viewed as a necessary evil by engineers who

would really rather spend more time testing and calculating. A realistic assessmentof the time and effort necessary to do a first class job of documentation can spellthe difference between a report that produces results and on the gathers dust on ashelf.

4.4 Monitoring of Energy Audit Results

The purpose of monitoring the energy audit results is to compare the effect of theapplied saving measures (practical and actual aspect) with the set targets (theoreticaland goals). The level of monitoring energy audits may range from no monitoring(just some random cases and sample projects) to actual monitoring of savingsachieved.


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Fundamental Audit

Although Fundamental Audit is the cheapest, it can yield a preliminary estimate of savings potential and a list of low-costsavings opportunities.

undamental Audit is the least costly audit among the other level of auditing. The fundamental audit is a tour of the facility to visually inspect eachsystem. Although this audit is the cheapest, it can yield a preliminaryestimate of savings potential and a list of low-cost savings opportunities

through improvements in operational and maintenance practices. The fundamentalaudit information may be used for a more detailed audit later if the preliminarysavings potential appears to warrant further auditing activity. The main objective ofthis fundamental audit is to provide an idea of an energy project’s potential prior tospending money on a detailed study. This chapter describes in detail the practicalaspect of the fundamental audit.

5.1 Audit InstrumentationIn this level of auditing, sophisticated and expensive instrumentation is not a mustor compulsory. If those tools are available, it would be an advantage and great helpin the auditing. A simple and easy to use tool is essential to give an overview of theenergy profile in the organization. Those tools are discussed below.

5.1.1 Measuring Electrical System Performance At this stage, the essential tool that will give you the information on theperformance of electrical system in the organization is the electrical bill. With theelectrical bills, you can identify and gather a handful of information regarding yourelectrical system performance throughout the whole year or a particular survey

period.

Besides, through frequent checking of electrical meter reading from the kWh meteron an interval period basis, a trend or ‘pattern’ of energy usage could be identified

within the organization. The gathering of those information could be done moreeasily if proper tools are being used. However, for a start, gathering of electricitybills and frequent checking are essential to gather the required information forauditing purposes.

Chapter

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5.1.2 Environmental Instruments The bulk of consumed energy is to enhance the organization comfort, in terms oflighting systems, HVAC, water heaters, etc. In order to gather those information,the environmental instruments are required, such as the sensor or logger fortemperature, relative humidity, light, thermocouple, etc. Nevertheless, the mainparameters that are sufficient for this level of audit are temperature, relativehumidity and light density. With these information, the level of comfort and theusage ‘pattern’ can be concluded and linked with the electrical performance system.

5.1.3 Other ToolsIn order to have an overview of the whole energy system in the organization, theright person to be interviewed is the plant, facility or maintenance personnel. Theyare the most knowledgeable person in the organization to know the ‘health’ of thebuilding energy system. Hence, an interview or survey form is required to gatherinformation from them. This form should be customized according to individualneeds and requirements.

5.2 Fundamental Audit Methodology

As discussed earlier in Chapter 3, the Fundamental Audit is a scanning model. Themain aims of a scanning are to point out areas, where energy saving possibilitiesexist (or may exist) and also to point out the most obvious saving measures whichare normally ‘good housekeeping’ and other no-cost measures. The fundamentalaudits do not go deeply into the profitability of the areas pointed out or into thedetails of the suggested measures. Before any action can be taken, the areaspointed out need to be analyzed further. The reason why the fundamental auditreport includes only a few suggestions that provide the client adequate informationfor implementation, is the very limited budget which does not allow thoroughanalysis, calculations or measurements.

The time spent on a fundamental audit depends naturally on the site and its size. The time spent on the audit itself is not a criterion to specify whether the model is afundamental audit or the other basic option, an analyzing audit. It is clear thatauditing a small tertiary building is totally different challenge than auditing a largeindustrial site. Therefore the fundamental audit can be carried out in a few hours ina small site but it may as well take one week or more at the other end of the scale.

The following is the suggested details procedure for the fundamental audit:-

I.

Define the Energy Audit properties (Refer to Figure 3.2)

a. Definition and Identification of Properties • Prior to other activity, the properties of energy audit should

be defined and identified so that there is a guideline andboundaries to this auditing.

b. Define all assumption and clarify all the necessary information


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• Any assumption and clarification should be defined in thissteps so to avoid confusion, miscommunication andsmooth process throughout the whole auditing.

II.

Measure , Monitor and Survey the site to determine current performance of energy

a. Interview with key facility personnel• A meeting with the key facility personnel to kick off the

project. The purpose is to establish the operatingcharacteristics of the facility, energy system specifications,operating and maintenance preliminary areas of invitation,unusual operating constraints, anticipated future plantexpansions or changes in product mix, and other concernsrelated to facility operations.

b. A brief review of facility utility bills and other operating data (ifavailable) for the 12 past months to 36 months (if available)

• Available facility documentation are reviewed with facilityrepresentatives. These documentations should include allavailable architectural and engineering plans, facilityoperation and maintenance procedures and logs, and utilitybills for the previous three years if applicable.

c. Facility tour with the audit instrumentation

• A tour of facility is arranged to observe the variousoperations first hand, focusing on the major energyconsuming systems including the architectural, lighting andpower, mechanical and process energy systems.

d.

Get the essential data from the site

III. Analyze and Evaluate the Energy Performancea. Compare the energy usage data with the utility bills through a

simple calculation as shown in Section 5.4.1.

• Simple calculation is essential for this level. A detailanalysis on energy usage should be covered in next level ofauditing.

b. Study the pattern of the room temperature in days or weeksthrough logger, and the usage of energy consumption for a yearfrom the utility bills. See example in Section 5.4.2.

• At this level, the utility analysis is a brief review of energybills from the previous 12 to 36 months. This shouldinclude all purchased energy, including electricity, naturalgas, fuel oil, liquefied petroleum gas (LPG) and purchasedsteam, as well as any energy generated on site. Billing datareviewed includes energy usage, energy demand and utilityrate structure.


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IV. Improve energy performance by identifying the possibilities steps in energy savinga. Simple corrective measures are briefly described. Refer to

Section 5.4.3.

• Some practical corrective measures which does notrequired huge investment could be proposed at this stage.

Those corrective measure can be as simple as creatingawareness among the staffs and personnel in theorganization on energy savings.

b. Brief recommendation on the next level of energy audit.

• The need of next level of auditing depending on the currentfinding. It also include which level of auditing and brieflydescribe the next level auditing properties; i.e. the goal &objective, the scope, the details of the survey and theduration & cost.

V.

Control future process performance by proper documentation in reporting andcontinuous monitoring

a. A brief reporting is sufficient for this stage.

• The results of the findings and recommendations aresummarized in a final report. It incorporates a summary ofall the activities and effort performed throughout theproject with specific conclusions and recommendations.

This report can also be proposed and presented to themanagement on the fate of the energy audit in theorganization.

b. This report should contain at least:i. A summary of the auditii. A check-list of tools usediii. Simple calculation from Section IIiv. Brief recommendation from Section III.

FIGURE 5.1 : Five Distinct DMAIC Steps of Fundamental Energy AuditProcedure


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The flow diagram for the above steps are shown in Figure 5.2.

FIGURE 5.2 : Steps Flow Diagram for Fundamental Audit

Define the Energy Audit Properties(Refer to Fig. 3.2)

a. Definition and

Identification ofProperties

b. Define all Assumptionsand Clarification

Measure Monitor andSurvey the site

Analyze and Evaluate the Energy Consumption

No

Yes

Control the Audit

Quality by reporting

a. Interview with key facility

personnela. A brief review of facility utility

bills and other operating data(if available) for the 12 pastmonths to 36 months (ifavailable)

b. Facility tour with the auditinstrumentation

c. Get the essential data from thesite

RequiredInformation

a. Compare the energyusage data with theutility bills

b. Study the pattern of theroom temperature andthe usage of energyconsumption

a. Simple correctivemeasures are brieflydescribed.

b. Brief recommendationon the next level ofener audit .

A brief reporting issufficient for this stage.

Reporting

Reporting

Reporting

Enough Data

for analysis?

Starts

Improve by Identifying the possibilities of Energy Saving


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5.3 Recommended Analysis and Practices

This section will demonstrates the recommended analysis, simple calculation andsuggested corrective measure for this level.

5.3.1 Calculating Load UseGenerally, the electric bill varies from month to month. The size of the electric billis determined by two things:

Watts, which is the amount of electricity that each load uses, and

Hours, or the length of time each load are being used

The combination of watts and hours - or kilowatt-hours (kWh) - is use to calculatethe bill for each month. So saving on the bill is as simple as reducing either the

wattage or the time of use an appliance.

To determine electric usage of your loads, follow these steps:

1. Find the wattage of the load.

2. Estimate hours of use per month.

3. Calculate the approximate number of kilowatt-hours each load uses byapplying this formula:

kWhWatts

Operationof HoursWatts=

×

1000

Example : You use a 1500-watt oven about 10 hours a month. Here’s how you would calculate electric usage:

kWhWatts

month per hoursWatts15

1000

101500=

×

5.3.1.1

Calculating cost

To calculate the annual cost to run an load by multiplying the kWh per year by therate per kWh consumed.

For example:

Exhaust fan: 200 Watts x 4 Hours used per day x 120 days used per year = 96 kWhx 8.5* cents/kWh =$8.16 per year.

* 8.5 cents is the rate we used for this example. Your actual rate is listed on your statement.


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5.3.2 Examples of Analysis Example 1: Pattern analysis of the room temperature with HOBO H8 Logger.Refer to Figure 5.3 for recorded data of room temperature for a period of about 24

hours.

FIGURE 5.3 : Historical Data for Room Temperature

From the diagram shown above, it can be concluded that during the period from1900 hours on 18 July 2001 till 0700 hours on 19 July 2001, the air-conditioner hasbeen switched off. The rise of temperature from 1900 hours till about 0200 hoursthe next day demonstrates that the room doors and windows are tightly closed.

When the air-conditioner is in operation, the energy consumption should increased,especially when it started to operate at about 0700 hours on 19 July 2001. Hence,the energy consumed should be quite similar ‘pattern’ as the temperature of theroom.

Example 2 : Pattern analysis of the room relative humidity with HOBO H8 Logger.Refer to Figure 5.4 for recorded data of room relative humidity for a period ofabout 24 hours.

As compare with Figure 5.3, the relative humidity varies according to the roomtemperature. When the temperature is low, the relative humidity is relatively low.


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FIGURE 5.4 : Historical Data for Room Relative Humidity

Example 3: Pattern analysis of the room lighting with HOBO H8 Logger. Refer toFigure 5.5 for recorded data of room lighting for a period of about 24 hours.

FIGURE 5.5 : Historical Data for Room Lighting

The historical data demonstrates a clear information regarding the light density interms of lumens per square feet (lum/sqf). Whether the light is switch on or offcan also determine through the diagram. The density for this room varies from 5-15 lum/sqf. A recommended corrective measure regarding light density will bediscussed in the following section.


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5.4 Recommended Corrective Measure by

Energy Market Authority, Singapore

5.4.1 Lighting

Check Purpose

1. Singapore StandardCode of Practice for Artificial Lighting inBuildings CP38 –1999.

Ensure that the lighting levels are within the recommended illuminationlevels in terms of glare & color rendition for the required tasks.

2. Use of Most EfficientLamp for Appropriate Task/Requirement

Use lamps with high luminous efficiency i.e. lumens/Watt as this saveselectricity. For example replacing incandescent bulbs with compactfluorescent lamps can reduce electricity consumption by 75% without any

reduction in illumination levels. Also when selecting lamps, other factorssuch as starting characteristics, color rendition, lifespan and locationshould be considered.

3. Fluorescent TubeBallasts

Consider replacing the standard conventional ballast (12W loss) withelectronic ballast (± 2W loss). The use of electronic ballast allows forsubstantial energy savings in the lighting system. Select those electronicballasts that comply with the Singapore Standard 380: Part 1: 1996 or theInternational Standards IEC 928 and 929.

4. Provision of SeparateSwitches forPeripheral Lighting

A flexible lighting system, which makes use of natural lighting for theperipherals of the room, should be considered so that these peripherallights can be switched off when not needed.

5. Lamp Fixtures orLuminaries

Reduce your lighting electricity consumption by as much as 50% withoutany reduction in illumination levels by using the optical lamp luminaries.Optical lamp luminaries made out of aluminum, silver or multipledielectric coatings have improved light distribution characteristics. Theseefficient luminaries reduce discomfort, glare and reflections. Also cleanthe lights and fixtures regularly. For best results, dust at least 4 times ayear.

6. Integration of LightingSystem With Air-Conditioning System

In open-plan offices, the air-conditioning and lighting systems can becombined in such a way that the return air is extracted through thelighting luminaries. This measure ensures that lesser heat will be directedfrom the lights into the room.

7. Use of Light Colorsfor Walls, Floors, andCeilings

The higher surface reflectance values of light colors will help to make themost of any existing lighting system.

8. Switch off Lights When Not in Use

Leaving a twin-fluorescent tube fitting switched on in an empty officeovernight wastes enough energy to heat water for 1,000 cups of coffee.


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5.4.2 Air-Conditioner

Check Purpose

1. Temperature andHumidity Settings

Ensure human comfort – not too cold or hot. The recommendedtemperature setting is between 23oC and 25oC while the relativehumidity should be equal to or less than 75%

2. Chilled Water Pipesand Air Ducts

Ensure that the insulation for the chilled water pipes and ductingsystem is maintained in good condition. This helps to prevent heatgain from the surroundings.

3. Chiller Condenser Tubes

The condition of the condenser tubes affects the energy efficiencyof the chiller. Fouling in condenser tubes, in the form of slime andscales, increases with time and reduces the heat transfer capacity ofthe condenser tubes. Mechanical cleaning should be carried out at

least once every 6 months.

4. Cooling Towers Ensure that the cooling towers are clean to allow for maximumheat transfer so that the temperature of the water returning to thecondenser is less than or equal to ambient temperature.

5. Air-handling UnitFan Speed

The fan motor is initially designed and installed to meet themaximum heat load of the room. However, during normaloperation, the fan will be operating at a level well below themaximum rated level. Explore the possibility of installing devicessuch as frequency converters to vary the fan speed therebyreducing the energy consumed by the fan motor. By installing

frequency converters, as much as 15% of the fan energyconsumption can be saved.

6. Air Filter Condition Maintain the filter in a clean condition by periodically removingdirt and solid particles that have settled on the cooling coils. This

will improve the heat transfer between air and chilled waterthereby reducing energy consumption.

7. Chilled WaterLeaving

Temperature

Ensure high chiller energy efficiency by maintaining a chilled waterleaving temperature at or above 7oC. As a rule of thumb, theefficiency of a centrifugal chiller increases by about 2¼ % forevery 1oC rise in the chilled water leaving temperature.


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5.4.3 Air-Compressor

Check Purpose

1. Load Characteristics Maximize the on-load time of the compressor. It is normal formost air-compressor motors to use as much as 1/

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